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Embrace your inner alter ego with these cosplay creations

This article was taken from the June 2015 issue of WIRED magazine. Be the first to read WIRED's articles in print before they're posted online, and get your hands on loads of additional content by subscribing online.

When Iron Man needs a new set of armour, or a Space Marine needs a chain gun, they turn to Shawn Thorsson. The Petaluma, California-based costume maker has built a reputation for his spectacular cosplay creations. His clients now include Hollywood studios, games developers and private commissions for superfans to wear to events such as London ComicCon.

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A former US Naval officer, Thorsson's first creation came about when he couldn't find a convincing Stormtrooper outfit one Halloween. "Ten months and two minor workshop fires later, I'd built my own vacuum forming machine and had a full set of armour," says the 37-year-old.

Each piece starts with Thorsson compiling visual references -- often using film stills or action figures – and measuring the person who will be wearing it. "If it's going to be sitting on a shelf, the build will be very different from something that needs to be able to do a martial-arts sequence," he says. He then goes about digital prototyping before fabricating each piece in his workshop. "I have a pair of CarveWright CNC machines for bigger pieces and an Objet30 3D printer for smaller parts," he says. The props themselves are often made from silicone, urethane and fibreglass -- just don't ask him to make armour from metal: "It might seem cool, but it's heavier and more expensive," he says. "The real art is making something lightweight and comfortable that looks convincing. It is, after all, a costume."

Among his favourite builds: full sets of Master Chief's Halo armour (with weapons, of course), and a pair of life-sized ED-209s from RoboCop. But his real dream: a full-scale recreation of the original Batmobile from Tim Burton's 1989 cult-classic film, Batman. "It's been on my to-do list for years,"he says. "I just need a bigger workshop."

This article was first published in the June 2015 issue of WIRED magazine